------Official DoS Install Instructions Available Here------

When I originally started this install, I hadn't yet received the instructions, so I thought I would document to potentially help some of you out. I got the instructions from Clint at DoS the next day, which are available at the link at the top. Here is my start to finish install and some tips along the way.

Here's the package and the contents. It came with a cool grille badge (pre-orders only? I don't know).



Here's is how all the parts fit together. Probably a good idea to assemble it ahead of time so you know where everything goes and don't get confused later.



First step is to remove your existing intake. For some, that will be the stock airbox, but for me it was the VIP intake. Either way, it's pretty easy. Stock airbox has one screw at the front passenger corner; the others 3 corners are friction fittings.



Here's a (blurry) pic of the VIP on the left, DoS in the middle, stock on the right. If you have a non-stock airbox, I hope you kept the hardware that came with it!



You'll need to reuse the rubber grommets that came with the stock airbox, as well as the single screw.



Once you have the intake out, the empty spot should look like this. If you're coming from the VIP, make sure you put the MAF sensor piece back in its original spot, like in the picture.



If you have the street version of the intake, you can install the DoS using the supplied hoses and clamps and call it a day. But if you have the performance version with the cowl induction piece, you've got more work ahead of you. First you'll need to remove 3 plastic nuts from each side of the engine bay. One is under the ratchet in the picture and the other two aren't far away. Also remove the weather stripping piece from the back of the engine bay. It just pops off.



Next there are 3 things clipped to the firewall piece that you'll need to unclip so you don't break them. First is this piece on the passenger side. Notice the angled clip piece; just turn it a bit counter-clockwise and it should pop out.



The second piece pops off with a bit of force.



The third thing is on the drivers side and has a release on one end (on the left in the picture). Press that and lift upward to free it.



Here you can see the top pieces starting to separate from the firewall piece.



Removing/replacing the firewall piece is the trickiest part of the install. The instructions say to remove the two top cowl pieces, but I couldn't get the wiper arms to come off, so that was impossible for me. The instructions mention a compact wiper arm removal tool, which would have been helpful. You should be able to leave the top cowl pieces on and not break anything if you can remove just the passenger wiper. Anyway, just wiggle the firewall piece around and eventually it will come out.



The main sticking point for me was this piece, which creates a partition between the battery and the rest of the cowl area. It really didn't want to come out and it's a bear to get it reinstalled.



You can see the damage I did to the passenger side cowl piece here. I'll have to get a replacement someday, though it's not urgent. It wouldn't have happened if the passenger wiper arm had been off. You could also remove the driver's wiper arm, but I didn't run into any issues on that side.



The next step is to cut a hole in the firewall to allow the intake to pull air from the cowl area. Here is a clip out of the DoS instructions



I don't own a 3.5" hole saw, so I used a hose clamp dialed out to 3.5" to mark the circle of what to cut.



Now use your favorite tool to cut out the hole. For me, it was dremel->hacksaw blade->dremel->sandpaper. It came out pretty well.



Next pop the rubber grommet piece into the newly created hole. You can see it here halfway in/halfway out.



Next pop in the snorkel piece with the ribbed pieces going into the engine bay side.



Next install the noise baffle if you so desire in the snorkel on the backside of the firewall piece and use the included zip tie to hold it in place.



Now reinstall the firewall piece, making sure you get the battery partition piece in place. Presumably it does something worthwhile. It should look like this.



Next rub some oil on the inside face of the grommet inside the intake housing, according to the instructions. Not really sure why, but the instructions said to. Then connect the snorkel to the grommet in the intake housing. Getting it all just right is tricky, and you'll probably want to take the filter element out so you can get your hand inside to align the pieces. It should look like this when you're done.



From here, it's smooth sailing. Use the short intake hose piece to connect the bottom of the intake and the elbow to connect to the MAF sensor. Tighten the one screw on the passenger front side, apply the decal if desired, and you're done.



The DoS intake fits fine with the VIP front strut brace.



The intake is a lot quieter than the VIP, but I think the car is pulling harder than before. I may remove the noise baffle to get more turbo sound back, but I really like the intake so far.

 

Good DIY. Hope you get it sorted out, especially after shelling out $350.

And for god's sake, man...clean that engine bay!

 

Too much dirt in New Mexico for it to stay clean long!

Reading a few other threads on here about removing the battery, it sounds like those top pieces just pull off. I'll try again tonight and see if I can get them free.

The intake is currently a lot quieter than the VIP. No turbo sounds on the way to work this morning :(

 

were you grabbing a hole saw to punch the firewall ?

.. i'm shocked it didn't come with directions could this have been an oversight, did you contact dos ?

 

Just got instructions from Clint about an hour ago, so I should be good now.

I don't think I have a hole saw that size, so I'll probably just use a dremel to cut it out and then smooth it up before installing the grommet piece. Finishing my own DIY probably isn't necessary at this point with the DoS instructions, but I'll take pictures and update the first post anyway. Can't hurt, and it might help someone down the road.

 

Finally got the install done this evening. I'll edit the first post with the full writeup tomorrow, but here's the final product:

 

It really is the nicest looking CAI.

 

Looks very nice and I trust Clint has done his homework on this thing. I loved my Gen1 CAI from DOS but I no longer have the Coupe so I'm selling it.

This install does raise the question though to those who may be going to the DOS from another aftermarket intake. If you have to rely on parts from the stock intake and you've sold/gotten rid of said intake you're somewhat screwed I presume. Ie. no rubber grommets. Not the end of the world but something to think about. Also, and I didn't see if it was recitfied in your post but that driver side post and grommet where it wasn't seated all the way. What's the point of having and using that post/grommet if it doesn't pop into the existing hole in the manifold cover ala stock air box? Anyway, just a couple questions. I'm looking at this intake as my next CAI for the Paceman but I do miss the smaller size of the Gen1 intake compared to this one.

 

After getting the snorkel installed, the front driver's side post snapped in, but the two toward the back of the engine bay aren't even close. I don't know why they're even there.

I have all the pictures resized, and I'll start working on words in a few minutes for the rest of the install. I can also post a link to the DoS instructions, which have the measurements for where to put the hole in the firewall.

 

thankyou. looking forward to it.

 

Okay, first post updated with steps from start to finish. Biggest tip is to get a wiper arm removal tool so you don't break the cowl piece like I did.

 

Great write up! I'll be breaking into my piggy bank in the near future!

 

I got a PM this week from someone asking about the snorkel and whether it would catch rain/snow/etc. I took this picture to show how far the snorkel goes past the cowl vent. Shouldn't be an issue.



Replaced the cracked passenger side cowl today, which was easy once the wiper arm was off. The whole firewall removal/reinstall steps would definitely have been much easier with it out of the way, though I still don't see any need to remove the driver side.

 

I remember the cowl rain question being a concern with the Gen 1 (R56+) DOS CAI as well. It wasn't an issue. Clint did sell a a hydrophobic cover for those that were paranoid but it was virtually impossible to get water in that thing. Looks the same here. Clint definitely doesn't just slap his products together unlike some (most) intakes on the market.

Great picture!!

Sent from my iPhone using NAMotoring

 

Where did you get the tool? Part number??

 

did you ever remove the noise baffle? results?

thanks

 

Yeah, I took it off when I took that picture of the snorkel back in September. It's definitely the way to go if you want to hear the turbo spin up/blow off.

 

I bought this one off of Amazon: